Fibrous structure product with high bulk

ABSTRACT

A fibrous structure product having two or more plies of fibrous structure having a High Load Caliper from 17 mils to about 45 mils. In addition a multiply fibrous structure product having two or more plies, a High Load Caliper from about 17 mils to about 45 mils; a basis weight from about 26 lbs/3000 ft 2  to about 50 lbs/3000 ft 2 ; and a Flex Modulus from about 0.1 to about 0.8.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/797,245 filed on May 3, 2006.

FIELD OF THE INVENTION

The present invention relates to fibrous structure products, morespecifically multi-ply fibrous structure products having multipleenhanced attributes and methods of making the same.

BACKGROUND OF THE INVENTION

Cellulosic fibrous structures are a staple of everyday life. Cellulosicfibrous structures are used as consumer products for paper towels,toilet tissue, facial tissue, napkins, and the like. The large demandfor such paper products has created a demand for improved versions ofthe products and the methods of their manufacture.

Consumers prefer cellulosic fibrous structure products having multipleattributes. These attributes include softness, absorbency, strength,flexibility, and bulk. Consumers may especially prefer fibrous structureproducts having higher bulk, including those having relatively highercaliper (thickness). These attributes may communicate to the consumerthat the product will be durable and strong, that the product will beuseful for a variety of cleaning tasks, that the product will last andperform throughout the cleaning process and retain its physicalintegrity during use, that the product will be absorbent, and/or basedon this performance, that the product has good value.

Usually, however, the improvement of one attribute, may compromise thequality of another attribute. For example, increasing bulk of a fibrousstructure may increase the absorbency while also increasing thestiffness of the product thereby decreasing the softness. Therefore,providing a product with improved bulk and therefore an improvedimpression of strength and durability without sacrificing the softnessand flexibility of the product is difficult.

Hence, the present invention unexpectedly provides a fibrous structureproduct with enhanced bulk and strength impression, providing a thick,high bulk quality cloth-like appearance. This is accomplished while alsoproviding an aesthetically pleasing flexible fibrous structure producthaving softness impression. The present invention provides a fibrousstructure that exhibits a particular range of bulk and caliper underhigh load as described herein, which unexpectedly provides a productwith enhanced durability and strength impression without sacrificingflexibility or softness attributes.

SUMMARY OF THE INVENTION

The present invention relates to a multiply fibrous structure productcomprising: two or more plies of fibrous structure wherein the fibrousstructure has a High Load Caliper of from 17 mils to about 45 mils. Thepresent invention further relates to a multiply fibrous structureproduct comprising: two or more plies of fibrous structure wherein thefibrous structure has a High Load Caliper of from about 17 mils to about45 mils; a basis weight is from about 26 lbs/3000 ft² to about 50lbs/3000 ft²; and a Flex Modulus of from about 0.1 to about 0.8.

The present invention further relates to a fibrous structure productcomprising: a single ply of fibrous structure having a High Load Caliperof from 18 mils to about 45 mils; a basis weight of from about 26lbs/3000 ft.² to about 40 lbs/3000 ft.²; and a Flex Modulus of fromabout 0.1 to about 0.8.

BRIEF DESCRIPTION OF THE DRAWINGS

Without intending to limit the invention, embodiments are described inmore detail below:

FIG. 1 is a fragmentary plan view of a multi-ply fibrous structureproduct displaying an embodiment of the present invention having domesformed during the paper making process, in a regular arrangement, and anembossment pattern on the first ply made according to the presentinvention.

FIG. 2 is a cross sectional view of a portion of the multi-ply fibrousstructure product shown in FIG. 1 as taken along line 4-4.

DETAILED DESCRIPTION OF THE INVENTION Definitions

As used herein, “paper product” refers to any formed, fibrous structureproducts, traditionally, but not necessarily, comprising cellulosefibers. In one embodiment, the paper products of the present inventioninclude tissue-towel paper products.

A “tissue-towel paper product” refers to products comprising papertissue or paper towel technology in general, including, but not limitedto, conventional felt-pressed or conventional wet-pressed tissue paper,pattern densified tissue paper, starch substrates, and high bulk,uncompacted tissue paper. Non-limiting examples of tissue-towel paperproducts include toweling, facial tissue, bath tissue, table napkins,and the like.

“Ply” or “Plies”, as used herein, means an individual fibrous structureor sheet of fibrous structure, optionally to be disposed in asubstantially contiguous, face-to-face relationship with other plies,forming a multi-ply fibrous structure. It is also contemplated that asingle fibrous structure can effectively form two “plies” or multiple“plies”, for example, by being folded on itself. In one embodiment, theply has an end use as a tissue-towel paper product. A ply may compriseone or more wet-laid layers, air-laid layers, and/or combinationsthereof. If more than one layer is used, it is not necessary for eachlayer to be made from the same fibrous structure. Further, the fibersmay or may not be homogenous within a layer. The actual makeup of atissue paper ply is generally determined by the desired benefits of thefinal tissue-towel paper product, as would be known to one of skill inthe art. The fibrous structure may comprise one or more plies ofnon-woven materials in addition to the wet-laid and/or air-laid plies.

The term “fibrous structure”, as used herein, means an arrangement offibers produced in any papermaking machine known in the art to create aply of paper. “Fiber” means an elongate particulate having an apparentlength greatly exceeding its apparent width. More specifically, and asused herein, fiber refers to such fibers suitable for a papermakingprocess.

“Basis Weight”, as used herein, is the weight per unit area of a samplereported in lbs/3000 ft² or g/m².

“Machine Direction” or “MD”, as used herein, means the directionparallel to the flow of the fibrous structure through the papermakingmachine and/or product manufacturing equipment.

“Cross Machine Direction” or “CD”, as used herein, means the directionperpendicular to the machine direction in the same plane of the fibrousstructure and/or fibrous structure product comprising the fibrousstructure.

“Sheet Caliper” or “Caliper”, as used herein, means the macroscopicthickness of a product sample under load.

“Densified”, as used herein, means a portion of a fibrous structureproduct that is characterized by having a relatively high-bulk field ofrelatively low fiber density and an array of densified zones ofrelatively high fiber density. The high-bulk field is alternativelycharacterized as a field of pillow regions. The densified zones arealternatively referred to as knuckle regions. The densified zones may bediscretely spaced within the high-bulk field or may be interconnected,either fully or partially, within the high-bulk field. One embodiment ofa method of making a pattern densified fibrous structure and devicesused therein are described in U.S. Pat. Nos. 4,529,480 and 4,528,239.

“Non-densified”, as used herein, means a portion of a fibrous structureproduct that exhibits a lesser density than another portion of thefibrous structure product.

“Bulk Density”, as used herein, means the apparent density of an entirefibrous structure product rather than a discrete area thereof.

“Laminating” refers to the process of firmly uniting superimposed layersof paper with or without adhesive, to form a multi-ply sheet.

“Non-naturally occurring” as used herein means that the fiber is notfound in nature in that form. In other words, some chemical processingof materials needs to occur in order to obtain the non-naturallyoccurring fiber. For example, a wood pulp fiber is a naturally occurringfiber, however, if the wood pulp fiber is chemically processed, such asvia a lyocell-type process, a solution of cellulose is formed. Thesolution of cellulose may then be spun into a fiber. Accordingly, thisspun fiber would be considered to be a non-naturally occurring fibersince it is not directly obtainable from nature in its present form.

“Naturally occurring fiber” as used herein means that a fiber and/or amaterial is found in nature in its present form. An example of anaturally occurring fiber is a wood pulp fiber.

Fibrous Structure Product

In one embodiment the fibrous structure has a High Load Caliper of fromabout 17 mils to about 45 mils; in another embodiment from about 18 milsto about 30 mils; in another embodiment from about 19 mils to about 28mils, and in another embodiment from about 20 mils to about 25 mils.

In one embodiment the fibrous structure product has a Flex Modulus fromabout 0.1 to about 0.8; in another embodiment from about 0.2 to about0.75; and in another embodiment from about 0.3 to about 0.7.

In one embodiment, the fibrous structure product has a basis weight ofgreater than about 26 lbs/3000 ft², in another embodiment from about 26lbs/3000 ft² to about 50 lbs/3000 ft². In another embodiment the basisweight is about 27 lbs/3000 ft² to about 40 lbs/3000 ft²; in anotherembodiment the basis weight is about 30 lbs/3000 ft² to about 40lbs/3000 ft² and in another embodiment the basis weight is about 32lbs/3000 ft² to about 37 lbs/3000 ft².

In one embodiment the fibrous structure product has a Wet Caliper ofgreater than about 18 or greater than about 25 mils; in anotherembodiment from about 18, 22, 27, 28 mils to about 30, 32, 35, 40 mils,or any combination of these ranges, as measured by the Wet Caliper TestMethod as disclosed herein.

In still yet another embodiment, the fibrous structure product exhibitsa sheet caliper or loaded caliper of at least about 29 mils, in anotherembodiment from about 30 mils to about 50 mils, and/or from about 33mils to about 45 mils, as measured by the Sheet Caliper Test Methoddisclosed herein.

In one embodiment the fibrous structure product exhibits a wet burststrength of greater than about 270 grams, in another embodiment fromabout 290 g, 300 g, 315 g to about 360 g, 380 g, 400 g, or anycombination of these ranges.

A nonlimiting example of an embossed multi-ply fibrous structure product100 in accordance with the present invention is shown in FIG. 1. Asshown in FIG. 1 a fragmentary plan view of a ply of multi-ply fibrousstructure 100 comprising two plies of fibrous structure wherein at leastone of the plies of the paper product has a plurality of domes 101formed by a resin coated woven belt during the papermaking process andordered in a regular arrangement. The domes may also be ordered in arandom arrangement. The exemplary multi-ply fibrous structure 100further comprises a non geometric foreground pattern 103 of embossments102 on the first ply (or may also be on the second ply according to thepresent invention. The embossments 102 form a latticework, defining aplurality of unembossed cells 104; wherein each cell comprises aplurality of domes 101 formed during the papermaking process.

The multi-ply fibrous structure product 100 in accordance with crosssection 4-4 of FIG. 1 is shown in FIG. 2. As shown in FIG. 2, themulti-ply fibrous structure product 100 comprises a first ply 201 and asecond ply 202 that are bonded together by an adhesive 203 along theadjacent inside first-ply surface 207 and inside second-ply surface 209at first-ply bond sites 206. The multi-ply fibrous structure product 100further comprises embossments 102. The cells 104 are not adhered to theadjacent ply. The cells 104 exhibit an embossment height, a, of fromabout 300 um to about 1500 um. The embossment height a extends in theZ-direction which is perpendicular to the plane formed in the machinedirection and the cross machine direction of the multi-ply fibrousstructure product 100. In one embodiment of the present invention, themulti-ply fibrous structure product 100 comprises an embossment height afrom about 300, 600, or 700 um to about 1,500 um, and in anotherembodiment from about 800 um or to about 1,000 or 1,500 um as measuredby the GFM MikroCAD optical profiler instrument described according toU.S. Application Nos. 2006/0005916A1, 2006/0013998A1. The bond sites 206may be densified or non-densified.

In one embodiment, because of the deformation caused by the embossments102 of the first ply 201, the extensibility of the second ply 202 ascompared to the first ply 201 constrains the first ply from beingelongated substantially in the cross machine direction plane of thepaper product. Suitable means of embossing include those disclosed inU.S. Pat. Nos. 3,323,983, 5,468,323, 5,693,406, 5,972,466, 6,030,690 and6,086,715.

As exemplified in FIGS. 1 and 2, the embossments on the multi-plyfibrous structure product 100 may be arranged to form a non geometricforeground pattern 103 or, in some embodiments, a curved latticework.The curved latticework of embossments can form an outline of aforeground pattern of unembossed cells in the latticework. The linesthat substantially describe each segment of the outline of theforeground pattern of embossments that form the latticework can be, butare not limited to, curved, wavy, snaking, S-waves, and sinusoidal. Thelatticework may form regular or irregular patterns. In one embodiment ofthe present invention, the embossments may be arranged to form one ormore non-geometric foreground patterns of unembossed cells wherein notwo cells are defined by the same embossments.

The present invention is equally applicable to all types of consumerpaper products such as paper towels, toilet tissue, facial tissue,napkins, and the like.

The present invention contemplates the use of a variety of paper makingfibers, such as, natural fibers, synthetic fibers, as well as any othersuitable fibers, starches, and combinations thereof. Paper making fibersuseful in the present invention include cellulosic fibers commonly knownas wood pulp fibers. Applicable wood pulps include chemical pulps, suchas Kraft, sulfite and sulfate pulps, as well as mechanical pulpsincluding, groundwood, thermomechanical pulp, chemically modified, andthe like. Chemical pulps may be used in tissue towel embodiments sincethey are known to those of skill in the art to impart a superiortactical sense of softness to tissue sheets made therefrom. Pulpsderived from deciduous trees (hardwood) and/or coniferous trees(softwood) can be utilized herein. Such hardwood and softwood fibers canbe blended or deposited in layers to provide a stratified web. Exemplarylayering embodiments and processes of layering are disclosed in U.S.Pat. Nos. 3,994,771 and 4,300,981. Additionally, fibers derived fromwood pulp such as cotton linters, bagesse, and the like, can be used.Additionally, fibers derived from recycled paper, which may contain anyof all of the categories as well as other non-fibrous materials such asfillers and adhesives used to manufacture the original paper product maybe used in the present web. In addition, fibers and/or filaments madefrom polymers, specifically hydroxyl polymers, may be used in thepresent invention. Non-limiting examples of suitable hydroxyl polymersinclude polyvinyl alcohol, starch, starch derivatives, chitosan,chitosan derivatives, cellulose derivatives, gums, arabinans, galactans,and combinations thereof. Additionally, other synthetic fibers such asrayon, polyethylene, and polypropylene fibers can be used within thescope of the present invention. Further, such fibers may be latexbonded.

In one embodiment the paper is produced by forming a predominantlyaqueous slurry comprising about 95% to about 99.9% water. In oneembodiment the non-aqueous component of the slurry used to make thefibrous structure comprises from about 5% to about 80% of eucalpyptusfibers by weight of the non-aqueous components of the slurry. In anotherembodiment the non-aqueous components comprises from about 8% to about60% of eucalpyptus fibers by weight of the non aqueous components of theslurry, and in yet another embodiment from about 12% to about 40% ofeucalpyptus fibers by weight of the non-aqueous component of the slurry.The aqueous slurry can be pumped to the headbox of the papermakingprocess.

In one embodiment the present invention may comprise a co-formed fibrousstructure. A co-formed fibrous structure comprises a mixture of at leasttwo different materials wherein at least one of the materials comprisesa non-naturally occurring fiber, such as a polypropylene fiber, and atleast one other material, different from the first material, comprisinga solid additive, such as another fiber and/or a particulate. In oneexample, a co-formed fibrous structure comprises solid additives, suchas naturally occurring fibers, such as wood pulp fibers, andnon-naturally occurring fibers, such as polypropylene fibers.

Synthetic fibers useful herein include any material, such as, but notlimited to polymers, those selected from the group consisting ofpolyesters, polypropylenes, polyethylenes, polyethers, polyamides,polyhydroxyalkanoates, polysaccharides, and combinations thereof. Morespecifically, the material of the polymer segment may be selected fromthe group consisting of poly(ethylene terephthalate), poly(butyleneterephthalate), poly(1,4-cyclohexylenedimethylene terephthalate),isophthalic acid copolymers (e.g., terephthalatecyclohexylene-dimethylene isophthalate copolymer), ethylene glycolcopolymers (e.g., ethylene terephthalate cyclohexylene-dimethylenecopolymer), polycaprolactone, poly(hydroxyl ether ester), poly(hydroxylether amide), polyesteramide, poly(lactic acid), polyhydroxybutyrate,and combinations thereof.

Further, the synthetic fibers can be a single component (i.e., singlesynthetic material or a mixture to make up the entire fiber),bi-component (i.e., the fiber is divided into regions, the regionsincluding two or more different synthetic materials or mixtures thereofand may include co-extruded fibers) and combinations thereof. It is alsopossible to use bicomponent fibers, or simply bicomponent or sheathpolymers. Nonlimiting examples of suitable bicomponent fibers are fibersmade of copolymers of polyester (polyethylene terephthalate)/polyester(polyethylene terephthalate) otherwise known as “CoPET/PET” fibers,which are commercially available from Fiber Innovation Technology, Inc.,Johnson City, Tenn.

These bicomponent fibers can be used as a component fiber of thestructure, and/or they may be present to act as a binder for the otherfibers present. Any or all of the synthetic fibers may be treatedbefore, during, or after the process of the present invention to changeany desired properties of the fibers. For example, in certainembodiments, it may be desirable to treat the synthetic fibers before orduring the papermaking process to make them more hydrophilic, morewettable, etc.

These multicomponent and/or synthetic fibers are further described inU.S. Pat. No. 6,746,766, issued on Jun. 8, 2004; U.S. Pat No. 6,946,506,issued Sep. 20, 2005; U.S. Pat. No. 6,890,872, issued May 10, 2005; USPublication No. 2003/0077444A1, published on Apr. 24, 2003; USPublication No. 2003/0168912A1, published on Nov. 14, 2002; USPublication No. 2003/0092343A1, published on May 15, 2003; USPublication No. 2002/0168518A1, published on Nov. 14, 2002; USPublication No. 2005/0079785A1, published on Apr. 14, 2005; USPublication No. 2005/0026529A1, published on Feb. 3, 2005; USPublication No. 2004/0154768A1, published on Aug. 12, 2004; USPublication No. 2004/0154767, published on Aug. 12, 2004; US PublicationNo. 2004/0154769A1, published on Aug. 12, 2004; US Publication No.2004/0157524A1, published on Aug. 12, 2004; US Publication No.2005/0201965A1, published on Sept. 15, 2005.

The fibrous structure may comprise any tissue-towel paper product knownin the industry. Embodiment of these substrates may be made accordingU.S. Pat. No. 4,191,609 issued Mar. 4, 1980 to Trokhan; U.S. Pat. No.4,300,981 issued to Carstens on Nov. 17, 1981; U.S. Pat. No. 4,191,609issued to Trokhan on Mar. 4, 1980; U.S. Pat. No. 4,514,345 issued toJohnson et al. on Apr. 30, 1985; U.S. Pat. No. 4,528,239 issued toTrokhan on Jul. 9, 1985; U.S. Pat. No. 4,529,480 issued to Trokhan onJul. 16, 1985; U.S. Pat. No. 4,637,859 issued to Trokhan on Jan. 20,1987; U.S. Pat. No. 5,245,025 issued to Trokhan et al. on Sep. 14, 1993;U.S. Pat. No. 5,275,700 issued to Trokhan on Jan. 4, 1994; U.S. Pat No.5,328,565 issued to Rasch et al. on Jul. 12, 1994; U.S. Pat. No.5,334,289 issued to Trokhan et al. on Aug. 2, 1994; U.S. Pat. No.5,364,504 issued to Smurkowski et al. on Nov. 15, 1995; U.S. Pat. No.5,527,428 issued to Trokhan et al. on Jun. 18, 1996; U.S. Pat. No.5,556,509 issued to Trokhan et al. on Sep. 17, 1996; U.S. Pat. No.5,628,876 issued to Ayers et al. on May 13, 1997; U.S. Pat. No.5,629,052 issued to Trokhan et al. on May 13, 1997; U.S. Pat. No.5,637,194 issued to Ampulski et al. on Jun. 10, 1997; U.S. Pat. No.5,411,636 issued to Hermans et al. on May 2, 1995; EP 677612 publishedin the name of Wendt et al. on Oct. 18, 1995, and U.S. PatentApplication 2004/0192136A1 published in the name of Gusky et al. on Sep.30, 2004.

The tissue-towel substrates may be manufactured via a wet-laid makingprocess where the resulting web is through-air-dried or conventionallydried. Optionally, the substrate may be foreshortened by creping or bywet microcontraction. Creping and/or wet microcontraction are disclosedin commonly assigned U.S. Pat. No. 6,048,938 issued to Neal et al. onApr. 11, 2000; U.S. Pat. No. 5,942,085 issued to Neal et al. on Aug. 24,1999; U.S. Pat. No. 5,865,950 issued to Vinson et al. on Feb. 2, 1999;U.S. Pat. No. 4,440,597 issued to Wells et al. on Apr. 3, 1984; U.S.Pat. No. 4,191,756 issued to Sawdai on May 4, 1980; and U.S. Pat. No.6,187,138 issued to Neal et al. on Feb. 13, 2001.

Conventionally pressed tissue paper and methods for making such paperare known in the art, for example U.S. Pat. No. 6,547,928 issued toBarnholtz et al. on Apr. 15, 2003. One suitable tissue paper is patterndensified tissue paper which is characterized by having a relativelyhigh-bulk field of relatively low fiber density and an array ofdensified zones of relatively high fiber density. The high-bulk field isalternatively characterized as a field of pillow regions. The densifiedzones are alternatively referred to as knuckle regions. The densifiedzones may be discretely spaced within the high-bulk field or may beinterconnected, either fully or partially, within the high-bulk field.Processes for making pattern densified tissue webs are disclosed in U.S.Pat. No. 3,301,746, issued to Sanford, et al. on Jan. 31, 1967; U.S.Pat. No. 3,974,025, issued to Ayers on Aug. 10, 1976; U.S. Pat. No.4,191,609, issued to on Mar. 4, 1980; and U.S. Pat. No. 4,637,859,issued to on Jan. 20, 1987; U.S. Pat. No. 3,301,746, issued to Sanford,et al. on Jan. 31, 1967; U.S. Pat. No. 3,821,068, issued to Salvucci,Jr. et al. on May 21, 1974; U.S. Pat. No. 3,974,025, issued to Ayers onAug. 10, 1976; U.S. Pat. No. 3,573,164, issued to Friedberg, et al. onMar. 30, 1971; U.S. Pat. No. 3,473,576, issued to Amneus on Oct. 21,1969; U.S. Pat. No. 4,239,065, issued to Trokhan on Dec. 16, 1980; andU.S. Pat. No. 4,528,239, issued to Trokhan on Jul. 9, 1985.

Uncompacted, non pattern-densified tissue paper structures are alsocontemplated within the scope of the present invention and are describedin U.S. Pat. No. 3,812,000 issued to Joseph L. Salvucci, Jr. et al. onMay 21, 1974; and U.S. Pat. No. 4,208,459, issued to Henry E. Becker, etal. on Jun. 17, 1980. Uncreped tissue paper as defined in the art arealso contemplated. The techniques to produce uncreped tissue in thismanner are taught in the prior art. For example, Wendt, et al. inEuropean Patent Application 0 677 612A2, published Oct. 18, 1995;Hyland, et al. in European Patent Application 0 617 164 A1, publishedSep. 28, 1994; and Farrington, et al. in U.S. Pat. No. 5,656,132 issuedAug. 12, 1997.

Uncreped tissue paper, in one embodiment, refers to tissue paper whichis non-compressively dried, by through air drying. Resultant through airdried webs are pattern densified such that zones of relatively highdensity are dispersed within a high bulk field, including patterndensified tissue wherein zones of relatively high density are continuousand the high bulk field is discrete. The techniques to produce uncrepedtissue in this manner are taught in the prior art. For example, Wendt,et. al. in European Patent Application 0 677 612A2, published Oct. 18,1995; Hyland, et. al. in European Patent Application 0 617 164 A1,published Sep. 28, 1994; and Farrington, et. al. in U.S. Pat. No.5,656,132 published Aug. 12, 1997.

Other materials are also intended to be within the scope of the presentinvention as long as they do not interfere or counteract any advantagepresented by the instant invention.

The substrate which comprises the fibrous structure of the presentinvention may be cellulosic, non-cellulosic, or a combination of both.The substrate may be conventionally dried using one or more press feltsor through-air dried. If the substrate which comprises the paperaccording to the present invention is conventionally dried, it may beconventionally dried using a felt which applies a pattern to the paperas taught by commonly assigned U.S. Pat. No. 5,556,509 issued Sep. 17,1996 to Trokhan et al. and PCT Application WO 96/00812 published Jan.11, 1996 in the name of Trokhan et al. The substrate which comprises thepaper according to the present invention may also be through air dried.A suitable through air dried substrate may be made according to commonlyassigned U.S. Pat. No. 4,191,609.

Plurality of Domes

In one embodiment at least one ply of fibrous structure comprises aplurality of domes formed during the papermaking process wherein the plycomprises from about 10 to about 1000 (i.e.; about 1.55 to about 155domes per square centimeter) domes per square inch of the ply. Inanother embodiment the ply comprises from about 25 to about 500 domesper square inch of the ply or product; in another embodiment the plycomprises from about 50 to about 300 and in another embodiment the plycomprises from about 120 to about 200 or from about 130 to about 160domes per square inch of the ply.

In one embodiment, the fibrous structure is through air dried on a belthaving a patterned framework. The belt according to the presentinvention may be made according to any of commonly assigned U.S. Pat.No. 4,637,859 issued Jan. 20, 1987 to Trokhan; U.S. Pat. No. 4,514,345issued Apr. 30, 1985 to Johnson et al.; U.S. Pat. No. 5,328,565 issuedJul. 12, 1994 to Rasch et al.; and U.S. Pat. No. 5,334,289 issued Aug.2, 1994 to Trokhan et al. The belts that result from the belt makingtechniques disclosed in the referenced patents provide advantages overconventional belts in the art and are herein referred to as resin coatedwoven belts.

In one embodiment, the patterned framework of the belt imprints apattern comprising an essentially continuous network onto the paper andfurther has deflection conduits dispersed within the pattern. Thedeflection conduits extend between opposed first and second surfaces ofthe framework. The deflection conduits allow domes to form in the paper.

In one embodiment, the fibrous substrate is a through air dried papermade according to the foregoing patents and has a plurality of domesformed during the papermaking process which are dispersed throughout anessentially continuous network region. The domes extend generallyperpendicular to the paper and increase its caliper. The domes generallycorrespond in geometry, and during papermaking in position, to thedeflection conduits of the belt described above. There are an infinitevariety of possible geometries, shapes, and arrangements for thedeflection conduits and the domes formed in the paper therefrom. Theseshapes include those disclosed in commonly assigned U.S. Pat. No.5,275,700 issued on Jan. 4, 1994 to Trokan. Examples of these shapesinclude, but are not limited to those described as a bow-tie pattern orsnowflake pattern. Further examples of these shapes include, but are notlimited to, circles, ovals, diamonds, triangles, hexagons, and variousquadrilaterals.

The domes protrude outwardly from the plane of the paper due to moldinginto the deflection conduits during the papermaking process. By moldinginto the deflection conduits during the papermaking process, the regionsof the paper comprising the domes are deflected in the Z-direction.

If the fibrous structure has domes, or other prominent features in thetopography, the domes, or other prominent feature, may be arranged in avariety of different configurations. These configurations include, butare not limited to: regular arrangements, random arrangements, multipleregular arrangements, and combinations thereof.

The fibrous structure product according to the present invention havingdomes may be made according to commonly assigned U.S. Pat. No. 4,528,239issued Jul. 9, 1985 to Trokhan; U.S. Pat. No. 4,529,480 issued Jul. 16,1985 to Trokhan; U.S. Pat. No. 5,275,700 issued Jan. 4, 1994 to Trokhan;U.S. Pat. No. 5,364,504 issued Nov. 15, 1985 to Smurkoski et al.; U.S.Pat. No. 5,527,428 issued Jun. 18, 1996 to Trokhan et al.; U.S. Pat. No.5,609,725 issued Mar. 11, 1997 to Van Phan; U.S. Pat. No. 5,679,222issued Oct. 21, 1997 to Rasch et al.; U.S. Pat. No. 5,709,775 issuedJan. 20, 1995 to Trokhan et al.; U.S. Pat. No. 5,795,440 issued Aug. 18,1998 to Ampulski et al.; U.S. Pat. No. 5,900,122 issued May 4, 1999 toHuston; U.S. Pat. No. 5,906,710 issued May 25, 1999 to Trokhan; U.S.Pat. No. 5,935,381 issued Aug. 10, 1999 to Trokhan et al.; and U.S. Pat.No. 5,938,893 issued Aug. 17, 1999 to Trokhan et al.

In one embodiment the fibrous structure is made using the papermakingbelt as disclosed in U.S. Pat. No. 5,334,289, issued on Aug. 2, 1994,Paul Trokhan and Glenn Boutilier.

In one embodiment the plies of the multi-ply fibrous structure may bethe same substrate respectively or the plies may comprise differentsubstrates combined to create desired consumer benefits. In oneembodiment the fibrous structures comprise two plies of tissuesubstrate. In another embodiment the fibrous structure comprises a firstply, a second ply, and at least one inner ply.

In one embodiment of the present invention, the fibrous structureproduct has a plurality of embossments. In one embodiment the embossmentpattern is applied only to the first ply, and therefore, each of the twoplies serve different objectives and are visually distinguishable. Forinstance, the embossment pattern on the first ply provides, among otherthings, improved aesthetics regarding thickness and quilted appearance,while the second ply, being unembossed, is devised to enhance functionalqualities such as absorbency, thickness and strength. In anotherembodiment the fibrous structure product is a two ply product whereinboth plies comprise a plurality of embossments.

Suitable means of embossing include those disclosed in U.S. Pat. No.3,323,983 issued to Palmer on Sep. 8, 1964; U.S. Pat. No. 5,468,323issued to McNeil on Nov. 21, 1995; U.S. Pat. No. 5,693,406 issued toWegele et al. on Dec. 2, 1997; U.S. Pat. No. 5,972,466 issued to Trokhanon Oct. 26, 1999; U.S. Pat. No. 6,030,690 issued to McNeil et al. onFeb. 29, 2000; and U.S. Pat. No. 6,086,715 issued to McNeil on Jul. 11.

Suitable means of laminating the plies include but are not limited tothose methods disclosed in commonly assigned U.S. Pat. No. 6,113,723issued to McNeil et al. on Sep. 5, 2000; U.S. Pat. No. 6,086,715 issuedto McNeil on Jul. 11, 2000; U.S. Pat No. 5,972,466 issued to Trokhan onOct. 26, 1999; U.S. Pat. No. 5,858,554 issued to Neal et al. on Jan. 12,1999; U.S. Pat. No. 5,693,406 issued to Wegele et al. on Dec. 2, 1997;U.S. Pat. No. 5,468,323 issued to McNeil on Nov. 21, 1995; U.S. Pat. No.5,294,475 issued to McNeil on Mar. 15, 1994.

The fibrous structure product may be in roll form. When in roll form,the fibrous structure product may be wound about a core or may be woundwithout a core.

Optional Ingredients

The multi-ply fibrous structure product herein may optionally compriseone or more ingredients that may be added to the aqueous papermakingfurnish or the embryonic web. These optional ingredients may be added toimpart other desirable characteristics to the product or improve thepapermaking process so long as they are compatible with the othercomponents of the fibrous structure product and do not significantly andadversely effect the functional qualities of the present invention. Thelisting of optional chemical ingredients is intended to be merelyexemplary in nature, and are not meant to limit the scope of theinvention. Other materials may be included as well so long as they donot interfere or counteract the advantages of the present invention.

A cationic charge biasing species may be added to the papermakingprocess to control the zeta potential of the aqueous papermaking furnishas it is delivered to the papermaking process. These materials are usedbecause most of the solids in nature have negative surface charges,including the surfaces of cellulosic fibers and fines and most inorganicfillers. In one embodiment the cationic charge biasing species is alum.In addition charge biasing may be accomplished by use of relatively lowmolecular weight cationic synthetic polymer, in one embodiment having amolecular weight of no more than about 500,000 and in another embodimentno more than about 200,000, or even about 100,000. The charge densitiesof such low molecular weight cationic synthetic polymers are relativelyhigh. These charge densities range from about 4 to about 8 equivalentsof cationic nitrogen per kilogram of polymer. An exemplary material isCypro 514®, a product of Cytec, Inc. of Stamford, Conn.

High surface area, high anionic charge microparticles for the purposesof improving formation, drainage, strength, and retention may also beincluded herein. See, for example, U.S. Pat. No. 5,221,435, issued toSmith on Jun. 22, 1993.

If permanent wet strength is desired, cationic wet strength resins maybe optionally added to the papermaking furnish or to the embryonic web.From about 2 to about 50 lbs./ton of dry paper fibers of the cationicwet strength resin may be used, in another embodiment from about 5 toabout 30 lbs./ton , and in another embodiment from about 10 to about 25lbs./ton.

The cationic wet strength resins useful in this invention includewithout limitation cationic water soluble resins. These resins impartwet strength to paper sheets and are well known to the paper making art.This resin may impart either temporary or permanent wet strength to thesheet. Such resins include the following Hercules products. KYMENE®resins obtainable from Hercules Inc., Wilmington, Del. may be used,including KYMENE® 736 which is a polyethyleneimine (PEI) wet strengthpolymer. It is believed that the PEI imparts wet strength by ionicbonding with the pulps carboxyl sites. KYMENE® 557LX is polyamideepichlorohydrin (PAE) wet strength polymer. It is believed that the PAEcontains cationic sites that lead to resin retention by forming an ionicbond with the carboxyl sites on the pulp. The polymer contains3-azetidinium groups which react to form covalent bonds with the pulps'carboxyl sites as well as with the polymer backbone. The product mustundergo curing in the form of heat or undergo natural aging for thereaction of the azentidinium group. KYMENE® 450 is a base activatedepoxide polyamide epichlorohydrin polymer. It is theorized that like557LX the resin attaches itself ionically to the pulps' carboxyl sites.The epoxide group is much more reactive than the azentidinium group. Theepoxide group reacts with both the hydroxyl and carboxyl sites on thepulp, thereby giving higher wet strengths. The epoxide group can alsocrosslink to the polymer backbone. KYMENE® 2064 is also a base activatedepoxide polyamide epichlorohydrin polymer. It is theorized that KYMENE®2064 imparts its wet strength by the same mechanism as KYMENE® 450.KYMENE® 2064 differs in that the polymer backbond contains more epoxidefunctional groups than does KYMENE® 450. Both KYMENE® 450 and KYMENE®2064 require curing in the form of heat or natural aging to fully reactall the epoxide groups, however, due to the reactiveness of the epoxidegroup, the majority of the groups (80-90%) react and impart wet strengthoff the paper machine. Mixtures of the foregoing may be used. Othersuitable types of such resins include urea-formaldehyde resins, melamineformaldehyde resins, polyamide-epichlorohydrin resins, polyethyleneimineresins, polyacrylamide resins, dialdehyde starches, and mixturesthereof. Other suitable types of such resins are described in U.S. Pat.No. 3,700,623, issued Oct. 24, 1972; U.S. Pat. No. 3.772,076, issuedNov. 13, 1973; U.S. Pat. No. 4,557,801, issued Dec. 10, 1985 and U.S.Pat. No. 4,391,878, issued Jul. 5, 1983.

In one embodiment, the cationic wet strength resin may be added at anypoint in the processes, where it will come in contact with the paperfibers prior to forming the wet web.

If enhanced absorbency is needed, surfactants may be used to treat thepaper webs of the present invention. The level of surfactant, if used,in one embodiment, from about 0.01% to about 2.0% by weight, based onthe dry fiber weight of the tissue web. In one embodiment thesurfactants have alkyl chains with eight or more carbon atoms. Exemplaryanionic surfactants include linear alkyl sulfonates and alkylbenzenesulfonates. Exemplary nonionic surfactants include alkylglycosidesincluding alkylglycoside esters such as Crodesta SL40® which isavailable from Croda, Inc. (New York, N.Y.); alkylglycoside ethers asdescribed in U.S. Pat. No. 4,011,389, issued to Langdon, et al. on Mar.8, 1977; and alkylpolyethoxylated esters such as Pegosperse 200 MLavailable from Glyco Chemicals, Inc. (Greenwich, Conn.) and IGEPALRC-520® available from Rhone Poulenc Corporation (Cranbury, N.J.).Alternatively, cationic softener active ingredients with a high degreeof unsaturated (mono and/or poly) and/or branched chain alkyl groups cangreatly enhance absorbency.

In addition, chemical softening agents may be used. In one embodimentthe chemical softening agents comprise quaternary ammonium compoundsincluding, but not limited to, the well-known dialkyldimethylammoniumsalts (e.g., ditallowdimethylammonium chloride, ditallowdimethylammoniummethyl sulfate (“DTDMAMS”), di(hydrogenated tallow)dimethyl ammoniumchloride, etc.). In another embodiment variants of these softeningagents include mono or diester variations of the before mentioneddialkyldimethylammonium salts and ester quaternaries made from thereaction of fatty acid and either methyl diethanol amine and/ortriethanol amine, followed by quaternization with methyl chloride ordimethyl sulfate.

Another class of papermaking-added chemical softening agents comprisesorgano-reactive polydimethyl siloxane ingredients, including the aminofunctional polydimethyl siloxane. The fibrous structure product of thepresent invention may further comprise a diorganopolysiloxane-basedpolymer. These diorganopolysiloxane-based polymers useful in the presentinvention span a large range of viscosities; from about 10 to about10,000,000 centistokes (cSt) at 25° C. Some diorganopolysiloxane-basedpolymers useful in this invention exhibit viscosities greater than10,000,000 centistokes (cSt) at 25° C. and therefore are characterizedby manufacturer specific penetration testing. Examples of thischaracterization are GE silicone materials SE 30 and SE 63 withpenetration specifications of 500-1500 and 250-600 (tenths of amillimeter) respectively.

Among the diorganopolysiloxane polymers of the present invention arediorganopolysiloxane polymers comprising repeating units, where saidunits correspond to the formula (R₂SiO)_(n), where R is a monovalentradical containing from 1 to 6 carbon atoms, in one embodiment selectedfrom the group consisting of methyl, ethyl, propyl, isopropyl, butyl,isobutyl, t-butyl, amyl, hexyl, vinyl, allyl, cyclohexyl, amino alkyl,phenyl, fluoroalkyl and mixtures thereof. The diorganopoylsiloxanepolymers which may be employed in the present invention may contain oneor more of these radicals as substituents on the siloxane polymerbackbone. The diorganopolysiloxane polymers may be terminated bytriorganosilyl groups of the formula (R′₃Si) where R′ is a monovalentradical selected from the group consisting of radicals containing from1-6 carbon atoms, hydroxyl groups, alkoxyl groups, and mixtures thereof.In one embodiment the silicone polymer is a higher viscosity polymers,e.g., poly(dimethylsiloxane), herein referred to as PDMS or siliconegum, having a viscosity of at least 100,000 cSt.

Silicone gums, optionally useful herein, corresponds to the formula:

$\frac{{--\left( {- {{Si—O}--}} \right)_{X}} -}{R}$

where R is a methyl group.

Fluid diorganopolysiloxane polymers that are commercially available,include SE 30 silicone gum and SF96 silicone fluid available from theGeneral Electric Company. Similar materials can also be obtained fromDow Corning and from Wacker Silicones.

An additional fluid diorganosiloxane-based polymer optionally for use inthe present invention is a dimethicone copolyol. The dimethiconecopolyol can be further characterized as polyalkylene oxide modifiedpolydimethysiloxanes, such as manufactured by the Witco Corporationunder the trade name Silwet. Similar materials can be obtained from DowComing, Wacker Silicones and Goldschmidt Chemical Corporation as well asother silicone manufacturers. Silicones useful herein are furtherdisclosed in U.S. Pat. Nos. 5,059,282; 5,164,046; 5,246,545; 5,246,546;5,552,345; 6,238,682; 5,716,692.

In addition antibacterial agents, coloring agents such as printelements, perfumes, dyes, and mixtures thereof, may be included in thefibrous structure product of the present invention.

EXAMPLES Example 1

One fibrous structure useful in achieving the fibrous structure paperproducts of the present invention is a through-air-dried (TAD),differential density structure formed by the following process.(Examples of TAD structures are generally described in U.S. Pat. No.4,528,239.)

A Fourdrinier, through-air-dried papermaking machine is used. A slurryof papermaking fibers is pumped to the headbox at a consistency of about0.15%. The slurry consists of about 70% Northern Softwood Kraft fibers,about 30% unrefined Eucalyptus fibers, a cationicpolyamine-epichlorohydrin wet burst strength resin at a concentration ofabout 25 lbs per ton of dry fiber, and carboxymethyl cellulose at aconcentration of about 5 lbs per ton of dry fiber, as well as DTDMAMS ata concentration of about 6 lbs per ton of dry fiber.

Dewatering occurs through the Fourdrinier wire and is assisted by vacuumboxes. The embryonic wet web is transferred from the Fourdrinier wire ata fiber consistency of about 20% at the point of transfer, to a TADcarrier fabric. The wire speed is about 620 feet per minute. The carrierfabric speed is about 600 feet per minute. Since the wire speed isfaster than the carrier fabric, wet shortening of the web occurs at thetransfer point. Thus, the wet web foreshortening is about 3%. The sheetside of the carrier fabric consists of a continuous, patterned networkof photopolymer resin, the pattern containing about 150 deflectionconduits or domes per square inch. The deflection conduits or domes arearranged in a regular configuration, and the polymer network coversabout 25% of the surface area of the carrier fabric. The polymer resinis supported by and attached to a woven support member. The photopolymernetwork rises about 18 mils above the support member.

The consistency of the web is about 60% after the action of the TADdryers operating about a 400° F., before transfer onto the Yankee dryer.An aqueous solution of creping adhesive is applied to the Yankee surfaceby spray applicators before the location of the sheet transfer. Thefiber consistency is increased to an estimated 95.5% before creping theweb with a doctor blade. The doctor blade has a bevel angle of about 25degrees and is positioned with respect to the Yankee dryer to provide animpact angle of about 81 degrees. The Yankee dryer is operated at about360° F., and Yankee hoods are operated at about 350° F.

The dry, creped web is passed between two calendar rolls and rolled on areel operated at 560 feet per minute so that there is about 7%foreshortening of the web by crepe.

The paper described above is then subjected to a knob-to-rubberimpression embossing process as follows. An emboss roll is engraved witha nonrandom pattern of protrusions. The emboss roll is mounted, alongwith a backside impression roll, in an apparatus with their respectiveaxes being generally parallel to one another. The emboss roll comprisesembossing protrusions which are frustaconical in shape. The backsideimpression roll is made of Valcoat™ material from Valley Roller Company,Mansfield, Tex. The paper web is passed through the nip to create anembossed ply.

The resulting paper has an embossment height of from about 600 μm toabout 950 μm, a High Load Caliper of about 20 mils, a Basis weight ofabout 34 lbs./3,000 ft.² to about 36 lbs./3,000 ft., and a Flex Modulusof about 0.6.

Example 2

One fibrous structure useful in achieving the fibrous structure paperproducts of the present invention is a through-air-dried (TAD),differential density structure formed by the following process.(Examples of TAD structures are generally described in U.S. Pat. No.4,528,239.)

A Fourdrinier, through-air-dried papermaking machine is used. A slurryof lo papermaking fibers is pumped to the headbox at a consistency ofabout 0.15%. The slurry consists of about 70% Northern Softwood Kraftfibers, about 20% unrefined Eucalyptus fibers, and about 10% ofbicomponent fibers of copolymers of polyester (polyethyleneterephthalate)/polyester (polyethylene terephthalate) such as“CoPET/PET” fibers, which are commercially available from FiberInnovation Technology, Inc., Johnson City, Tenn. The slurry furthercomprises a cationic polyamine-epichlorohydrin wet burst strength resinat a concentration of about 25 lbs per ton of dry fiber, andcarboxymethyl cellulose at a concentration of about 5 lbs per ton of dryfiber, as well as DTDMAMS at a concentration of about 6 lbs per ton ofdry fiber.

Dewatering occurs through the Fourdrinier wire and is assisted by vacuumboxes. The embryonic wet web is transferred from the Fourdrinier wire ata fiber consistency of about 24% at the point of transfer, to a TADcarrier fabric. The wire speed is about 620 feet per minute. The carrierfabric speed is about 600 feet per minute. Since the wire speed isfaster than the carrier fabric, wet shortening of the web occurs at thetransfer point. Thus, the wet web foreshortening is about 3%. The sheetside of the carrier fabric consists of a continuous, patterned networkof photopolymer resin, the pattern containing about 150 deflectionconduits or domes per square inch. The deflection conduits or domes arearranged in a regular configuration, and the polymer network coversabout 25% of the surface area of the carrier fabric. The polymer resinis supported by and attached to a woven support member. The photopolymernetwork rises about 18 mils above the support member.

The consistency of the web is about 72% after the action of the TADdryers operating about a 350° F., before transfer onto the Yankee dryer.An aqueous solution of creping adhesive is applied to the Yankee surfaceby spray applicators before location of sheet transfer. The fiberconsistency is increased to an estimated 97% before creping the web witha doctor blade. The doctor blade has a bevel angle of about 25 degreesand is positioned with respect to the Yankee dryer to provide an impactangle of about 81 degrees. The Yankee dryer is operated at about 500°F., and Yankee hoods are operated at about 380° F.

The dry, creped web is passed between two calendar rolls and rolled on areel operated at 560 feet per minute so that there is about 7%foreshortening of the web by crepe.

The paper described above is then subjected to a knob-to-rubberimpression embossing process as follows. An emboss roll is engraved witha nonrandom pattern of protrusions. The emboss roll is mounted, alongwith a backside impression roll, in an apparatus with their respectiveaxes being generally parallel to one another. The emboss roll comprisesembossing protrusions which are frustaconical in shape. The backsideimpression roll is made of Valcoat™ material from Valley Roller Company,Mansfield, Tex. The paper web is passed through the nip to create anembossed ply.

The resulting paper has an embossment height of from about 600 μm toabout 950 μm, a High Load Caliper of about 22 mils, a Basis Weight ofabout 35 lbs/3000 ft.² and a Flex Modulus of about 0.5.

Test Methods

The following describe the test methods utilized herein to determine thevalues consistent with those presented herein. All measurements for thetest methods are made at 23±1° C. and 50% ±2% relative humidity, unlessotherwise specified.

Flex Modulus

The Flex Modulus is a measurement of the bending stiffness of thefibrous structure product herein. The following procedure can be used todetermine the bending stiffness of paper product. The KawabataEvaluation System-2, Pure Bending Tester (i.e.; KES-FB2, manufactured bya Division of Instrumentation, Kato Tekko Company, Ltd. of Kyoto, Japan)may be used for this purpose.

Samples of the paper product to be tested are cut to approximately 20×20cm in the machine and cross machine direction. The sample width ismeasured to 0.01 inches (0.025 cm). The outer ply (i.e.; the ply that isfacing outwardly on a roll of the paper sample) and inner ply aspresented on the roll are identified and marked.

The sample is placed in the jaws of the KES-FB2 Auto A such that thesample is first bent with the outer ply undergoing compression and theinner ply undergoing tension. In the orientation of the KES-FB2 theouter ply is right facing and the inner ply is left facing. The distancebetween the front moving jaw and the rear stationary jaw is 1 cm. Thesample is secured in the instrument in the following manner. First thefront moving chuck and the rear stationary chuck are opened to acceptthe sample. The sample is inserted midway between the top and bottom ofthe jaws such that the machine direction of the sample is parallel tothe jaws (i.e.; vertical in the KES-FB2 holder).

The rear stationary chuck is then closed by uniformly tightening theupper and lower thumb screws until the sample is snug, but not overlytight. The jaws on the front stationary chuck are then closed in asimilar fashion. The sample is adjusted for squareness in the chuck,then the front jaws are tightened to insure the sample is held securely.The distance (d) between the front chuck and the rear chuck is 1 cm.

The output of the instrument is load cell voltage (Vy) and curvaturevoltage (Vx). The load cell voltage is converted to a bending momentnormalized for sample width (M) in the following manner:

Moment(M,gf*cm/cm)=(Vy*Sy*d)/W

where Vy is the load cell voltage; Sy is the instrument sensitivity ingf*cm/V; d is the distance between the chucks; and W is the sample widthin centimeters.

The sensitivity switch of the instrument is set at 5×1. Using thissetting the instrument is calibrated using two 50 gram weights. Eachweight is suspended from a thread. The thread is wrapped around the baron the bottom end of the rear stationary chuck and hooked to a pinextending from the front and back of the center of the shaft. One weightthread is wrapped around the front and hooked to the back pin. The otherweight thread is wrapped around the back of the shaft and hooked to thefront pin. Two pulleys are secured to the instrument on the right andleft side. The top of the pulleys are horizontal to the center pin. Bothweights are then hung over the pulleys (one on the left and one on theright) at the same time. The full scale voltage is set at 10 V. Theradius of the center shaft is 0.5 cm. Thus the resultant full scalesensitivity (Sy) for the Moment axis is 100 gf*0.5 cm/10V (5 gf*cmnV).

The output for the Curvature axis is calibrated by starting themeasurement motor and manually stopping the moving chuck when theindicator dial reaches the stop . The output voltage (Vx) is adjusted to0.5 volts. The resultant sensitivity (Sx) for the curvature axis is2/(volts*cm). The curvature (K) is obtained in the following manner:

Curvature(K,cm⁻¹)=Sx*Vx

where Sx is the sensitivity of the curvature axis; and Vx is the outputvoltage.

For determination of the bending stiffness the moving chuck is cycledfrom a curvature of 0 cm⁻¹ to +2.5 cm⁻¹ to −2.5 cm⁻¹ to 0 cm⁻¹ at a rateof 0.5 cm⁻¹/sec. Each sample is cycled once. The output voltage of theinstrument is recorded in a digital format using a personal computer. Atthe start of the test there is no tension on the sample. As the testbegins the load cell begins to experience a load as the sample is bent.The initial rotation is clockwise when viewed from the top down on theinstrument.

The load continues to increase until the bending curvature reachesapproximately +2.5 cm⁻¹ (this is the Forward Bend (FB)). Atapproximately +2.5 cm⁻¹ the direction of rotation was reversed. Duringthe return the load cell reading decreases. This is the Forward BendReturn (FR). As the rotating chuck passes 0, curvature begins in theopposite direction. The Backward Bend (BB) and Backward Bend Return (BR)is obtained.

The data was analyzed in the following manner. A linear regression lineis obtained between approximately 0.2 and 0.7 cm⁻¹ for the Forward Bend(FB). The slope of the line is reported as the Bending Stiffness (B) orFlex Modulus, in units of gf*cm²/cm. The method is repeated with thesample oriented such that the cross direction is parallel to the jaws.Three or more separate samples are run. The reported values are theaverages of the BFB on the MD and CD samples. This method is alsodescribed in U.S. Pat. No. 6,602,577B1.

Sheet Caliper or Loaded Caliper Test Method

Samples are conditioned at 23±1° C. and 50% relative humidity for twohours prior to testing.

Sheet Caliper or Loaded Caliper of a sample of fibrous structure productis determined by cutting a sample of the fibrous structure product suchthat it is larger in size than a load foot loading surface where theload foot loading surface has a circular surface area of about 3.14 in².The sample is confined between a horizontal flat surface and the loadfoot loading surface. The load foot loading surface applies a confiningpressure to the sample of 14.7 g/cm² (about 0.21 psi). The caliper isthe resulting gap between the flat surface and the load foot loadingsurface. Such measurements can be obtained on a VIR Electronic ThicknessTester Model II available from Thwing-Albert Instrument Company,Philadelphia, Pa. The caliper measurement is repeated and recorded atleast five (5) times so that an average caliper can be calculated. Theresult is reported in mils.

Wet Caliper Test Method

Samples are conditioned at 23±1° C. and 50% relative humidity for twohours prior to testing. Wet Caliper of a sample of fibrous structureproduct is determined by cutting a sample of the fibrous structureproduct such that it is larger in size than a load foot loading surfacewhere the load foot loading surface has a circular surface area of about3.14 in². Each sample is wetted by submerging the sample in a distilledwater bath for 30 seconds. The caliper of the wet sample is measuredwithin 30 seconds of removing the sample from the bath. The sample isthen confined between a horizontal flat surface and the load footloading surface. The load foot loading surface applies a confiningpressure to the sample of 14.7 g/cm² (about 0.21 psi). The caliper isthe resulting gap between the flat surface and the load foot loadingsurface. Such measurements can be obtained on a VIR Electronic ThicknessTester Model II available from Thwing-Albert Instrument Company,Philadelphia, Pa. The caliper measurement is repeated and recorded atleast five (5) times so that an average caliper can be calculated. Theresult is reported in mils.

High Load Caliper and Compression Slope

Caliper versus load data are obtained using a Thwing-Albert Model EJAMaterials Tester, equipped with a 2000 g load cell and compressionfixture. The compression fixture consisted of the following; load celladaptor plate, 2000 gram overload protected load cell, load celladaptor/foot mount 1.128 inch diameter presser foot, #89-14 anvil,89-157 leveling plate, anvil mount, and a grip pin, all available fromThwing-Albert Instrument Company, Philadelphia, Pa. The compression footis one square inch in area. The instrument is run under the control ofThwing-Albert Motion Analysis Presentation Software (MAP V1,1,6,9). Asingle sheet of a conditioned sample is cut to a diameter ofapproximately two inches. Samples are conditioned for a minimum of 2hours at 23±1° C. and 50±2% relative humidity. Testing is carried outunder the same temperature and humidity conditions. The sample must beless than 2.5-inch diameter (the diameter of the anvil) to preventinterference of the fixture with the sample. Care should be taken toavoid damage to the center portion of the sample, which will be undertest. Scissors or other cutting tools may be used. For the test, thesample is centered on the compression table under the compression foot.The compression and relaxation data are obtained using a crosshead speedof 0.1 inches/minute. The deflection of the load cell is obtained byrunning the test without a sample being present. This is generally knownas the Steel-to-Steel data. The Steel-to-Steel data are obtained at acrosshead speed of 0.005 in/min. Crosshead position and load cell dataare recorded between the load cell range of 5 grams and 1500 grams forboth the compression and relaxation portions of the test. Since the footarea is one square inch this corresponded to a range of 5 grams/sq in to1500 grams/sq in. The maximum pressure exerted on the sample is 1500g/sq in. At 1500 g/sq in the crosshead reverses its travel direction.Crosshead position values are collected at 31 selected load valuesduring the test. These correspond to pressure values of 10, 25, 50, 75,100, 125, 150, 200, 300, 400, 500, 600, 750, 1000, 1250, 1500, 1250,1000, 750, 500, 400, 300, 250, 200, 150, 125, 100, 75, 50, 25, 10 g/sq.in. for the compression and the relaxation direction. During thecompression portion of the test, crosshead position values are collectedby the MAP software, by defining fifteen traps (Trap 1 to Trap 15) atload settings of 10, 25, 50, 75, 100, 125, 150, 200, 300, 400, 500, 600,750, 1000, 1250. During the return portion of the test, crossheadposition values are collected by the MAP software, by defining fifteenreturn traps (Return Trap 1 to Return Trap 15) at load settings of 1250,1000, 750, 500, 400, 300, 250, 200, 150, 125, 100, 75, 50, 25, 10. Thethirty-first trap is the trap at max load (1500 g). Again values areobtained for both the Steel-to-Steel and the sample. Steel-to-Steelvalues are obtained for each batch of testing. If multiple days areinvolved in the testing, the values are checked daily. TheSteel-to-Steel values and the sample values are an average of fourreplicates (1500 g).

Caliper values are obtained by subtracting the average Steel-to-Steelcrosshead trap values from the sample crosshead trap value at each trappoint. For example, the values from two, three, or four individualreplicates on each sample are averaged and used to obtain plots of theCaliper versus Load and Caliper versus Log(10) Load.

The Compression Slope is defined as the absolute value of the initialslope of the caliper versus Log(10)Load. The value is calculated bytaking four data pairs from the compression direction of the curve thatis, the caliper at 500, 600, 750, 1,000 or 750, 1,000, 1250, 1500, g/sqin at the start of the test. The pressure is converted to the Log(10) ofthe pressure. A least square regression is then obtained using the fourpairs of caliper (y-axis) and Log(10) pressure (x-axis). The absolutevalue of the slope of the regression line is the Compression Slope. Theunits of the Compression Slope are mils/(log(10)g/sq in). For simplicitythe Compression Slope is reported here without units. High Load Caliperis the average caliper at 1,500 g/sq. inch.

Wet Burst Strength Test Method

“Wet Burst Strength” as used herein is a measure of the ability of afibrous structure and/or a fibrous structure product incorporating afibrous structure to absorb energy, when wet and subjected todeformation normal to the plane of the fibrous structure and/or fibrousstructure product.

Wet burst strength may be measured using a Thwing-Albert Burst TesterCat. No. 177 equipped with a 2000 g load cell commercially availablefrom Thwing-Albert Instrument Company, Philadelphia, Pa.

Wet burst strength is measured by taking two (2) multi-ply fibrousstructure product samples. Using scissors, cut the samples in half inthe MD so that they are approximately 228 mm in the machine directionand approximately 114 mm in the cross machine direction, each two (2)plies thick (you now have 4 samples). First, condition the samples fortwo (2) hours at a temperature of 73° F.±2° F. (about 23° C.±1° C.) anda relative humidity of 50% ±2%. Next age the samples by stacking thesamples together with a small paper clip and “fan” the other end of thestack of samples by a clamp in a 105° C. (±1° C.) forced draft oven for5 minutes (±10 seconds). After the heating period, remove the samplestack from the oven and cool for a minimum of three (3) minutes beforetesting. Take one sample strip, holding the sample by the narrow crossmachine direction edges, dipping the center of the sample into a panfilled with about 25 mm of distilled water. Leave the sample in thewater four (4) (±0.5) seconds. Remove and drain for three (3) (±0.5)seconds holding the sample so the water runs off in the cross machinedirection. Proceed with the test immediately after the drain step. Placethe wet sample on the lower ring of a sample holding device of the BurstTester with the outer surface of the sample facing up so that the wetpart of the sample completely covers the open surface of the sampleholding ring. If wrinkles are present, discard the samples and repeatwith a new sample. After the sample is properly in place on the lowersample holding ring, turn the switch that lowers the upper ring on theBurst Tester. The sample to be tested is now securely gripped in thesample holding unit. Start the burst test immediately at this point bypressing the start button on the Burst Tester. A plunger will begin torise toward the wet surface of the sample. At the point when the sampletears or ruptures, report the maximum reading. The plunger willautomatically reverse and return to its original starting position.Repeat this procedure on three (3) more samples for a total of four (4)tests, i.e., four (4) replicates. Report the results as an average ofthe four (4) replicates, to the nearest g.

All measurements referred to herein are made at 23±1° C. and 50% ±2%relative humidity, unless otherwise specified.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A multiply fibrous structure product comprising: two or more plies offibrous structure having a High Load Caliper from 17 mils to about 45mils.
 2. The product of claim 1 wherein the High Load Caliper is fromabout 18 mils to about 30 mils.
 3. The product of claim 2 wherein theHigh Load Caliper is from about 19 mils to about 25 mils.
 4. The productof claim 3 wherein the basis weight is from 27 lbs/3000 ft² to about 40lbs/3000 ft².
 5. The product of claim 1 wherein at least one of theplies comprises from about 10 to about 1000 domes per square inch of theproduct, the domes formed during the papermaking process.
 6. The productof claim 5 wherein the ply comprises from about 50 to about 300 domesper square inch of the product.
 7. The product of claim 5 wherein thefibrous structure further comprises from about 8% to about 60% ofeucalyptus fibers.
 8. The product of claim 1 wherein the Wet Caliper isgreater than about 18 mils.
 9. The product of claim 8 wherein the WetCaliper is from about 28 mils to about 35 mils.
 10. The product of claim1 wherein the sheet caliper is from about 29 mils to about 50 mils. 11.The product of claim 10 wherein the sheet caliper is from about 33 milsto about 45 mils.
 12. The product of claim 1 wherein the fibrousstructure product further comprises a chemical softening agent at alevel of from about 0.05 lbs/ton to about 6 lbs/ton of furnish.
 13. Theproduct of claim 12 wherein the chemical softening agent is selectedfrom the group consisting of quaternary ammonium compounds,organo-reactive polydimethyl siloxane compounds, and mixtures thereof.14. The product of claim 13 wherein the chemical softening agent isselected from the group consisting of dialkyldimethylamnmonium salts,ditallowdimethylammonium chloride, ditallowdimethylammonium methylsulfate, di(hydrogenated tallow)dimethyl ammonium chloride, mono ordiester variations of the dialkyldimethylammonium, and mixtures thereof.15. The product of claim 1, wherein at least one of the plies of fibrousstructure comprises creped or uncreped through-air-dried fibrousstructure plies, differential density fibrous structure plies, wet laidfibrous structure plies, air laid fibrous structure plies, conventionalfibrous structure plies and combinations thereof.
 16. The product ofclaim 15 wherein the ply comprises a creped through-air dried tissuepaper.
 17. The product of claim 1 wherein at least one of the piles hasa plurality of embossments.
 18. A multiply fibrous structure productcomprising: two or more plies of fibrous structure having a High LoadCaliper from about 17 mils to about 45 mils; a basis weight from about26 lbs/3000 ft² to about 50 lbs/3000 ft² ; and a Flex Modulus from about0.1 to about 0.8.
 19. The product of claim 18 wherein the High LoadCaliper is from about 18 mils to about 30 mils.
 20. The product of claim19 wherein the High Load Caliper is from about 19 mils to about 25 mils.21. The product of claim 18 wherein the basis weight is from 27 lbs/3000ft² to about 40 lbs/3000 ft².
 22. The product of claim 18 wherein theFlex Modulus is from about 0.2 to about 0.75.
 23. The product of claim22 wherein the Flex Modulus is from about 0.3 to about 0.7.
 24. Theproduct of claim 18 wherein at least one of the plies comprises fromabout 10 to about 1000 domes per square inch of the product the domesformed during the papermaking process.
 25. The product of claim 24wherein the ply comprises from about 50 to about 300 domes per squareinch of the product.
 26. The product of claim 24 wherein the fibroussubstrate comprises from about 8% to about 60% of eucalyptus fibers. 27.The product of claim 18 wherein the fibrous structure product furthercomprises a chemical softening agents selected from the group consistingof quaternary ammonium compounds, organo-reactive polydimethyl siloxanecompounds, and mixtures thereof.
 28. The product of claim 27 wherein thechemical softening agent is selected from the group consisting ofdialkyldimethylamnmonium salts, ditallowdimethylammonium chloride,ditallowdimethylammonium methyl sulfate, di(hydrogenated tallow)dimethylammonium chloride, mono or diester variations of thedialkyldimethylammonium, and mixtures thereof.
 29. A fibrous structureproduct comprising: a single ply of fibrous structure having a High LoadCaliper from 18 mils to about 45 mils; a basis weight from about 26lbs/3000 ft.² to about 40 lbs/3000 ft.²; and a Flex Modulus from about0.1 to about 0.8.